Installation/processing systems, methods, and components

ABSTRACT

A processing tool to process workpieces, for example cold working holes and/or installing expandable members into holes includes an expansion assembly with a plurality of elongated expansion segments. A first band and a second band couple the expansion segments into an array with the expansion segments circumferentially distributed about a longitudinal axis, with a passageway extending between the arrayed segments. The processing tool may include a tuning assembly that allows a radial expansion amount of the expansion assembly to be adjusted without altering a stroke length of a drive member of the processing tool. Sensors may sense various aspects of the processing performed by the processing tool to enable analysis and storage of information regarding performance of the process and/or materials processed by the processing tool.

BACKGROUND

1. Field

This disclosure generally relates to installation/processing systems for installing expandable members into holes in workpieces and/or cold expanding holes in workpieces.

2. Description of the Related Art

Conventional installation tools are used to install bushings in holes within workpieces. These installation tools often have an expansion mandrel with an enlarged tapered portion used to expand the bushing. To radially expand the bushing, the expansion mandrel is inserted into an opening in the bushing. The bushing and mandrel are simultaneously inserted into a hole in a workpiece. When the bushing is positioned in the hole of the workpiece, the enlarged tapered portion of the mandrel extends outwardly from the backside of the workpiece. These types of installation tools thus require an adequate amount of backside clearance and are unsuitable for installing bushings in non-through holes, blind holes, or other holes having limited backside clearance.

To expand the bushing, the enlarged tapered portion of the mandrel is forcibly pulled axially through the opening of the bushing until an interference fit is formed between the bushing and workpiece. Unfortunately, relatively high frictional forces can be generated as the mandrel is moved through the bushing. These forces may cause the bushing to move relative to the workpiece, thus resulting in improper positioning of the installed bushing. Additionally, as the mandrel is pulled through the bushing, the outer surface of the mandrel can abrade the sidewall of the bushing's opening, thereby reducing the quality of the installed bushing.

Other installation tools use a threaded installation member to install a partially collapsible fastener element. The partially collapsible fastener element is inserted into a through hole in a workpiece until a first flange at a trailing end of the fastener element is in contact with a front face of the workpiece. Unfortunately, a collapsible portion of the fastener element has to extend outwardly from the backside of the workpiece, thus requiring a through hole having sufficient backside clearance.

Once the fastener element is positioned in the workpiece, an externally threaded end of the threaded installation member is inserted into an opening in the fastener element from the front side of the workpiece. The installation member is threadably mated with internal threads of the fastener element such that both the installation member and fastener element extend beyond the backside of the workpiece.

A tubular mandrel surrounding the installation member is moved into contact with an entrance of the opening in the fastener element. An actuator (e.g., pusher, puller) device retracts the installation member through the tubular mandrel to cause the collapsible portion (e.g., a reduced thickness wall portion) of the fastener element to collapse and form a second flange on the backside of the workpiece. The workpiece is thus sandwiched between the first and second flanges of the fastener element. Unfortunately, during this process, the actuator device is pulled against the front surface of the workpiece and may deform, mar, or otherwise degrade the front surface of the workpiece.

The tubular mandrel is moved axially into the opening of the fastener element causing radial expansion of a portion of the fastener element. The portion of the fastener element is radially expanded against the sidewall of the opening to form an interference fit. During this expansion process, the mandrel directly contacts and slides against the fastener element and, consequently, can undesirably abrade and damage the surface of the fastener element.

Consequently, conventional installation tools may not adequately meet certain quality and installation needs.

BRIEF SUMMARY

As noted above, it has been observed that the longitudinal motion of a mandrel passing through an opening has several disadvantages relating to space requirements as well as abrasion of the workpiece and/or an element that is to be installed. In addition, it has been observed that the mandrel can drag or push material, depending on the actuation direction, to either end of an installed component or workpiece as the mandrel is moved longitudinally through an opening. It may require addition steps to remove such material.

One solution has been to employ expandable structures that are inserted into holes and then expanded while in the hole. Such expandable structures typically include a plurality of elements or jaws that are arranged around an expansion mandrel, secured to each other at a proximal end, and free at a distal end. Moving the expansion mandrel longitudinally causes the expandable structures to separate from each other and expand.

It has been observed that conventional expandable structures are caused to pivot during expansion about the fixed, proximal end. Such pivoting results in non-uniform expansion in a radial direction along a longitudinal direction of the hole in which the expandable structure is inserted.

It has been further observed that an expansion assembly that includes a plurality of elongated expansion segments in which a first band and a second band couple the expansion segments into an array with the expansion segments circumferentially distributed about a longitudinal axis can achieve uniform radial expansion along the longitudinal direction of the hole in which the expansion assembly is installed. Further, such a configuration avoids the problems associated with expansion by dragging or pulling a mandrel through the hole.

In effect, it has been observed that a two band configuration may advantageously allow the outer surfaces of the expansion segments to expandable equally along the entire length of the expansion segments (i.e., move radially without pivoting).

Further, it has been observed that the inclusion of the bands on either side of a center point of a length of the individual expansion segments may allow for easier retention of the segments to a core element up to and during expansion. In particular, it has been observed that if only a single band is used on one end of the expansion segments, the opposite, non-banded end of the expansion elements may skew relative to the core element, resulting in non-uniform expansion forces. For example, such skewing may result in a spiral expansion.

It has further been observed that more uniform expansion in the radial direction results in less growth or more controlled growth of expandable members (e.g., tubular bushings, grommets, fittings, sleeves, etc.) installed in an opening of a workpiece. Such control may reduce or eliminate the need to install expandable members “flush to over flush,” and may reduce or eliminate the need to trim the installed product after installation.

In some embodiments, an expansion assembly includes a plurality of elongated expansion segments. Each of the expansion segments have a contact surface and a drive surface. A first band and a second band couple the expansion segments into an array with the expansion segments circumferentially distributed about a longitudinal axis, with a passageway extending between the arrayed segments.

The first band and the second band may be located on proximate ends of the expansion segments with respect to a length of the array. The first band and the second band may be located on opposite sides of a center of a length of the array. The expansion may further include a core element that is movable within the passageway along the longitudinal axis from a first position to a second position to drive each respective one of the plurality of expansion segments in a respective radial direction substantially transverse to the longitudinal axis. The passageway may include a first taper that is defined by the bearing surfaces of the plurality of expansion segments, and the core element may include a second taper. The first taper and the second taper may be non-conical tapers. The drive surface of each of the plurality of expansion segments may define a portion of the first taper, and the second taper of the drive member may include a plurality of planar bearing surfaces that each respectively corresponds to one of the drive surfaces of one of the plurality of complementary segments and which define a portion of the second taper. The core may have a polygonal cross section with respect to a central axis of the core.

In some embodiments, the expansion assembly may further include a core element that is movable within the passageway along the longitudinal axis to expand the expansion segments without pivoting by physical interaction between the core element and the drive surfaces of the plurality of expansion segments. Each of the plurality of expansion segments may include a portion of linearly decreasing thickness along the longitudinal axis. The drive surface of each of the plurality of expansion segments may be a bevel that extends in a plane oblique to the longitudinal axis. The expansion segments may each include a respective first and second retainer, and, in use, the first band and the second band are located in respective ones of the first and second retainers. At least one of the first and second retainers may be groove in an outer surface of at least one of the plurality of expansion segments. Each of the plurality of expansion elements may include a flange that extends radially outward with respect to the contact surface, and the flange is located between the first band and the second band. The expansion assembly may further include a nose cap including an interior face and through hole. A retaining member may be seated within the adjustment cap so that the flange of each of the plurality of expansion elements is secured between the retaining member and the interior face of the nose cap. The expansion assembly may include four of the expansion segments.

Observation has been made that an operator may be required to change a tooling setup to accommodate a variety of scenarios that arise during a single project. A single job may require expanding different holes with different materials. Different materials may have differing mechanical strengths or may be more or less crack prone. In another example, if a workpiece has a large hole tolerance, there may be a wide range of hole sizes that need to be worked. Likewise, there may be a varied range of material thicknesses across a workpiece that is to be cold-worked. It has been observed that each of these scenarios may require an operator to apply a different expansion amount to different holes on the same job, which may necessitate the operator to change the setup in order to achieve the desired expansion. Further, it has been observed that if mixed materials are used in a stack-up that is to be cold-worked, it may be necessary to perform at least two work steps using separate tooling for each step to accommodate different expansion amounts for each material. Such changes in setup are not only time consuming, but also require the operator to have access to multiple tooling setups, which can be costly.

A tuning assembly that allows an operator to adjust a radial expansion amount without altering a stroke amount of a drive system of a processing tool would be advantageous for many reasons. For example, the same setup can be used for a variety of scenarios. Likewise, once the expansions system is properly tuned, an operator can simply fully stroke the drive system, thus ensuring that the appropriate amount of force is applied to work the workpiece at the appropriate expansion amount. In effect, such a tuning assembly would allow a drive system to be fully stroked while nevertheless achieving different amounts of selected radial expansion using the same tool.

A tuning assembly for use in a processing system that includes an expansion assembly including a plurality of expansion elements, and a drive member that is movable in a longitudinal direction to actuate each respective one of the plurality of expansion segments of the expansion assembly in a respective radial direction substantially transverse to a longitudinal axis of the expansion assembly, the longitudinal direction being substantially parallel to the longitudinal axis, may be summarized as including a mechanism configured to selectively adjust a maximum radial expansion amount of the expansion assembly without altering a stroke length of the drive member.

The expansion segments of the expansion system are arranged circumferentially in an array distributed about the longitudinal axis, with a passageway extending between the arrayed expansion segments. The expansion assembly may include a core element movable in the passageway in the longitudinal direction to drive each respective one of the plurality of expansion segments in the respective radial direction by physical interaction between the core element and drive surfaces of the plurality of expansion segments, and the tuning mechanism may be configured to translate the expansion segments relative to the core element along the longitudinal axis. The processing system may further include a housing that houses the drive member. The tuning assembly may be coupled to the housing for selective movement with respect to the housing in the longitudinal direction, and the plurality of expansion segments are coupled to the housing so as to be fixed with respect to the housing in the longitudinal direction. The tuning assembly may be rotatable about the longitudinal axis relative to the housing between a plurality of fixed positions, each fixed position corresponding to a different maximum radial expansion amount of the expansion assembly. The tuning assembly may include a tuning cylinder that is fixed relative to the plurality of expansion segments in the longitudinal direction, and the tuning cylinder may be selectively movable relative to a housing that houses the drive member in the longitudinal direction. The tuning assembly may further include an index ring that is coupled to the tuning cylinder, the index ring fixed relative to the tuning cylinder with respect to a rotational direction about the longitudinal axis. The index ring may be selectively engageable with the housing at plurality of fixed positions in the rotational direction, each fixed position corresponding to a different maximum radial expansion amount of the expansion assembly. The expansion segments may be circumferentially distributed in an array about a longitudinal axis, with a passageway extending between the arrayed segments, the expansion assembly may include a core element movable in the passageway in the longitudinal direction to drive each respective one of the plurality of expansion segments in the respective radial direction by physical interaction between the core element and drive surfaces of the plurality of expansion segments, and the tuning assembly may be configured to adjust a depth of penetration in the longitudinal direction of the core element into the passageway.

A processing system to process at least a workpiece can be summarized as including an expansion assembly including a plurality of expansion elements; a drive member that is movable in a longitudinal direction to actuate each respective one of the plurality of expansion segments of the expansion assembly in a respective radial direction substantially transverse to a longitudinal axis of the expansion assembly, the longitudinal direction being substantially parallel to the longitudinal axis; and a tuning assembly configured to selectively adjust a maximum radial expansion amount of the expansion assembly without altering a stroke length of the drive member.

A processing system to process at least a workpiece can be summarized as including a plurality of elongated expansion segments distributed about a longitudinal axis; a core element sized and shaped to move the expansion segments away from each other as the core element is moved along the longitudinal axis; and at least one sensor responsive to at least one of a position of the core element, a distance of travel of the core element, a pressure, an applied force, or a reaction force resulting from an applied force applied directly or indirectly by the expanding of the expansion segments to the interior surface of the hole of a workpiece.

Each of the expansion segments may have a contact surface and a drive surface, and the expansion segments may contact an interior surface of a hole of a workpiece as the core element is moved along the longitudinal axis and bears against the drive surface of the expansion segments. At least one sensor may include a pressure sensor mounted to the expansion tool. At least one sensor may include a linear variable differential transducer.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

In the drawings, identical reference numbers identify similar elements or acts. The sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes of various elements and angles are not drawn to scale, and some of these elements are arbitrarily enlarged and positioned to improve drawing legibility. Further, the particular shapes of the elements as drawn, are not intended to convey any information regarding the actual shape of the particular elements, and have been solely selected for ease of recognition in the drawings.

FIG. 1 is an isometric view of a processing tool which is coupled to an expansion assembly, and a tuning assembly, according to one illustrated embodiment.

FIG. 2 is a partial cross-sectional view of the processing tool, expansion assembly, and tuning assembly of FIG. 1 taken along 2-2 of FIG. 1, in an expanded state.

FIG. 3 is a partial cross-sectional view of the processing tool, expansion assembly, and tuning assembly of FIG. 1 taken along 2-2 of FIG. 1, in a retracted state.

FIG. 4A is an exploded isometric view of the processing tool, expansion assembly, and tuning assembly of FIG. 1.

FIG. 4B is reverse isometric view of an index ring of the tuning assembly.

FIG. 5 is an exploded cross-sectional view of the processing tool, expansion assembly, and tuning assembly of FIG. 1.

FIG. 6 is an isometric view of a pressure transducer that can be coupled to the processing tool, according to one illustrated embodiment.

FIG. 7 is an isometric view of a linear variable differential transformer that can be coupled to the processing tool, according to one illustrated embodiment.

FIG. 8A is a partial cross-sectional view of portions of the processing tool and expansion assembly, and workpiece of FIG. 1 taken along 2-2 of FIG. 1, in a retracted state.

FIG. 8B is a partial cross-sectional view of portions of the processing tool and expansion assembly, and workpiece of FIG. 1 taken along 2-2 of FIG. 1, in an expanded state.

DETAILED DESCRIPTION OF THE INVENTION

In the following description, certain specific details are set forth in order to provide a thorough understanding of various embodiments of the invention. However, one skilled in the art will understand that the invention may be practiced without these details.

Unless the context requires otherwise, throughout the specification and claims which follow, the word “comprise” and variations thereof, such as, “comprises” and “comprising” are to be construed in an open, inclusive sense, that is as “including, but not limited to.”

The headings provided herein are for convenience only and do not interpret the scope of meaning of the claimed invention. The following description relates to installation/processing systems used to install expandable members (e.g., tubular bushings, grommets, fittings, sleeves, etc.) in openings, such as non-through holes in workpieces. The systems can also be used to process workpieces, such as cold working holes in workpieces. For purposes of this discussion and for clarity, a processing system for installing an expandable member will be described, and then a description of its components will follow. The term “processing system” is a broad term and includes, without limitation, a system that can be used to expand an expandable member, material surrounding a hole in a workpiece, or other suitable expandable structures. In some embodiments, processing systems are installation systems that install bushings in workpieces. The processing systems can also be in the form of cold expansion systems used to cold expand holes in workpieces with, or without, installing an expandable member. The terms “proximal” and “distal” are used to describe the illustrated embodiments and are used consistently with a description of non-limiting exemplary applications. The terms “proximal” and “distal” are used in reference to the user's body when the user operates a processing system, unless the context clearly indicates otherwise. It will be appreciated, however, that the illustrated embodiments can be located or oriented in a variety of desired positions.

The term processing system should not be confused with the term “processor-based system” which is used herein to denominate systems that include a processor such as a microprocessor, microcontroller, digital signal processors (DSPs), application specific integrated circuit (ASIC), programmed logic controller (PCL), programmable gate array (PGA) for instance a field programmable gate array (FPGA) or other controllers. Notably, in many implementations a processing system may be a processor-based system.

I. Overview

FIGS. 1-4 shows a processing tool 100, an expansion assembly 200 physically coupled to the processing tool 100, and a tuning assembly 300 coupled between the processing tool 100 and the expansion assembly 200. Generally, the illustrated processing tool 100 may be used for one-sided or two-sided installation of an expandable member (not depicted) such as a bushing or rivetless nut plate (generically expandable member) in a hole (not depicted) in a primary workpiece (not depicted). A plurality of expansion segments 220 of the expansion assembly 200 can be controllably expanded in order to expand and install the expandable member. After installation, the expansion segments 220 can be controllably contracted to separate the expansion assembly 200 from the installed expandable member. The expandable member is sometimes referred to herein as a secondary workpiece, since processing may be performed in the expandable member in installing the expandable member at least partially in the hole of the primary workpiece.

As noted above, the processing system can be used in procedures involving workpieces. As used herein, the term “primary workpiece” or sometimes just “workpiece” is broadly construed to include, without limitation, a parent structure having at least one hole or opening suitable for processing (e.g., receiving an expandable member, undergoing cold expansion, etc.). The hole can be, for example, a through hole, non-through hole, blind hole, counter bore, or other types of holes that may or may not have backside access. In some embodiments, the primary workpiece is a bulkhead, fuselage, engine or other structural member of an aircraft, even if there is limited or no backside access. In some embodiments, the primary workpiece itself may be suitable for expansion (e.g., cold expansion) and may or may not be suitable for receiving an expandable member.

In the present example, the processing tool 100 is driven hydraulically. For example, the processing tool 100 may be fluidly communicatively coupled to a pressurization system (not depicted) which includes a source of pressurized fluid (not depicted), for instance one or more hydraulic reservoirs (not depicted) and/or pumps (not depicted) via a distribution system such as a hydraulic distribution system including one or more fluid carrying conduits, valves, and/or manifolds. The pressurization system may be of any conventional design, thus is not described in detail in the interest of brevity. Notably, other sources of power or drive capable of producing the required or desired forces may be employed. Further, the present disclosure is not limited to hydraulically driven processing tools, and is also applicable to processing tools that are driven electrically, pneumatically, or by any other suitable drive structures, mechanisms or engines.

The illustrated processing tool 100 includes a cylinder 120 that is coupled to a grip 110. A rear housing element 140 and an end cap are mounted on a rear end of the cylinder 120, and a front housing cap 160 is mounted on a front end of the cylinder 120. The user can manually grasp the grip 110 to controllably hold and accurately position the processing tool 100 with respect to a primary workpiece. The grip 110 is illustrated as a pistol grip, however, other types of grips can be utilized. The processing tool 100 may include a trigger 112 or other switch to activate the processing tool 100. For example, the trigger 112 can be a rocker switch that controls forward or rearward motion of a drive system of the processing tool 100. The trigger 112 can also be a button, momentary contact switch, or other switch that only requires one touch for activation. In a system that does not include electronic controls, the forward and back motion of the drive system of the process tool 100 can be controlled by air logic. In an electronically controlled system, motion of the drive system following activation of the switch can be controlled by a controller and software in a manner described in U.S. provisional patent application Ser. No. 61/592,500, entitled “SMART INSTALLATION/PROCESSING SYSTEMS, COMPONENTS, AND METHODS OF OPERATING THE SAME,” and U.S. non-provisional patent application Ser. Nos. 13/750,604 and 13/750,607, the contents of each of which are incorporated by reference herein in their entirety.

The cylinder 120 houses a drive system that can drive a mandrel or core element 210 of the expansion assembly 200 with respect to the expansion segments 220 of the expansion assembly 200. The drive system can have a push/pull piston arrangement and may comprise a double acting piston 130 in combination with the hydraulic cylinder 120. Other cylinder arrangements are also possible.

A pair of fluid conduits or lines 114 (only one is visible) can provide pressurized fluid (e.g., pressurized gas, liquid, or combinations thereof) to the drive system and/or relieve pressurized fluid from the drive system via the fluid paths 116 in the grip. In the present example, the fluid lines 114 can provide pressurized hydraulic fluid.

The drive system can be activated to drive the core element 210 along a predetermined path. The predetermined path can be a generally linear path (e.g., a line of action) extending in a proximal and a distal direction.

As illustrated in FIGS. 1-4, the expansion assembly 200 may include a core element 210 and a plurality of expansion segments 220. The expansion segments 220 include elongated bodies and a flange 226. As best understood from a review of FIGS. 2, 5, 8A and 8B, the expansion segments 220 are seated in a nose cap 170 such that the flanges 226 are secured between an inner surface 174 of the nose cap 170 and a retention devices 230 that is also seated in the nose cap 170. The elongated portion of the expansion segments 220 extends through a hole 172 in the front of the nose cap 170. The core element 210 is positioned to be driven by the drive system, and to physically interact with the expansion segments 220 to expand and the retract the expansion segments 220 in response to the core element 210 being driven by the drive system (in this case, the piston 130). In this example, the core element 210 includes a threaded portion 216 that engages a rod of the piston 130.

As used herein, the terms “core element” and “mandrel” are broad terms that include, but are not limited to, an elongated member configured to expand a plurality of expansion segments 220. The core element 210 can have a one-piece or multi-piece construction. In some embodiments, the core element has one or more surfaces (e.g., enlarged and/or tapered portions) which can interact with the expansion segments 220 so as to cause expansion of at least a portion of the expansion segments 220.

As illustrated, the expansion segments 220, with a passageway 240 defined therebetween to engagingly receive the core element 210. The expansion segments 220 may each form a portion of a cylinder or annulus, for example each forming approximately a quarter section of a cylinder. When viewed from either a proximate or distal end, or longitudinally, the arrangement or array of expansion segments 220 may have an approximately circular or oval outer perimeter. The inner perimeter may be polygonal.

In operation, the outer perimeter of the expansion segments 220 engage an expandable member (not depicted), or a primary workpiece 500 (FIGS. 8A and 8B) if no expandable member is to be used. There may be small gaps between adjacent edges of neighboring expansion segments 220 prior to expansion, which gaps increase as the expansion segments 220 are radially expanded outwardly in response to translation of the core element 210 outwardly with respect to the processing tool 100. Alternatively, the adjacent edges may be in contact with one another prior to radial expansion, essentially eliminating any gaps.

In the implementation illustrated in the figures, an inner surface 222 of the expansion segments 220 may be beveled or angled along at least a portion of a length of the expansion segment 220 (e.g., from proximate end to distal end thereof). The bevel or angle may, for example, complement a bevel or angle of the outer surfaces 212 of the core element 130. Such causes the inner surface 222 of the expansion segments 220 to interact with the outer surfaces 212 of the core element 210 to cause the expansion segments 220 to radially expand outwardly without pivoting of the expansion segments 220. Such may also cause the expansion segments 220 to radially withdraw or retract inwardly without pivoting of the expansion segments 220. Thus, each expansion segment 220 may move perpendicularly or transversely with respect to a centerline, longitudinal axis or center or a body or revolution of the expansion segments 220.

The expansion segments 220 may be expandably coupled to one another, for example via one or more bands 250 a, 250 b (FIGS. 8A and 8B) mounted in retainers 228 a and 228 b. Two expandable members may couple the expansion segments 220 together at two points along a length of the expandable assembly 200. The expandable members can take the form of, for example a spring retaining clip made from, for example, steel; an o-ring made from, for example, an elastomeric material; or any other suitable expandable, elastic element made of any suitable material as will be readily apparent to one having ordinary skill in the art upon review of this entire disclosure. This may advantageously allow the outer surfaces of the expansion segments 220 to expandable equally along the entire length of the expansion segments 220 (i.e., move radially without pivoting). This may advantageously eliminate or at least reduce any pivoting that would occur, such as pivoting that would occur were the expansion segments defined in a unitary structure. Further, the inclusion of the bands on either side of a center point of a length of the individual expansion segments may allow for easier retention of the segments to the core element up to and during expansion. In particular, if only a single band is used on one end of the expansion segments, the opposite, non-banded end of the expansion elements may skew relative to the core element, resulting in non-uniform expansion forces. For example, such skewing may result in a spiral expansion.

The core element 210 can be moved distally along a path from an initial position (shown in FIGS. 3 and 8A) to an extended position (shown in FIGS. 2 and 8B) to expand the expansion segments 220 from a first configuration to a second configuration. For example, the core element 210 can drive the expansion segments 220 from a radially retracted, withdrawn or collapsed configuration to a radially expanded configuration.

The partially or fully extended core element 210 can also be retracted. When the extended core element 210 moves proximally towards its initial position, the expansion segments 220 retract, withdraw or collapses inwardly. The bands may bias or urge the expansion segments 220 of the expandable assembly 200 toward the radially retracted, withdrawn or collapsed configuration. Once the core element 210 is pulled out of the expansion segments 220, the expansion segments 220 may return to their fully retracted, withdrawn or collapsed configuration. In this manner, the expansion segments 220 can be repeatedly moved between the expanded and the retracted, withdrawn or collapsed configurations.

The process tool 100 may also include an indicator to alert the operator that the actuator has reached the full forward position for which it was calibrated. For example, an electronic control system may include one or more visual indications which may indicate when a drive member or actuator has reached a full forward position, which may be a position calibrated using an optional tuning assembly. Alternatively, where pressure is employed to supply control signals to a processing tool, an indicator may take a mechanical form, for example a popup indicator that has a signal member which pops up in response to full travel of the drive member being achieved.

Optionally, a sleeve (not shown) may be positioned in the passageway 240 defined by the expansion segments 220, which may form a protective liner between the core element 210 and at least a portion of the expansion segments 210. Optionally, a lubricant may be provided between the core element 210 and/or the expansion segments 220. Optionally, a surface of either or both of the core element 210 and/or the expansion segments 220 of the expansion segments 220 may be coated or treated to be lubricious for example treated with a tungsten based coating such as the commercially available under the trademark ULTRALUBE®.

FIGS. 1-4 further depict a tuning assembly 300 disposed between the processing tool 100 and the expansion assembly 200. The tuning assembly 300 advantageously allows an operator to adjust a radial expansion amount of the expansion assembly 200 without altering a stroke amount of the drive system of the processing tool 100. For example, the tuning assembly 300 can adjust a penetration depth of the core element 210 into the expansion segments 220 by linearly translating the expansion segments 220 relative to the core element 210. This arrangement allows the piston 130 to be fully stroked while nevertheless achieving different amounts of selected radial expansion using the same tool.

Advantageously, the tuning assembly 300 gives operators the ability to adjust to multiple scenarios without needing to switch to new tooling. For example, if a single job requires different materials to be worked, which may have differing mechanical strengths or may be more or less crack prone, the tuning assembly 300 allows the operator to adjust the expansion amount accordingly without require multiple setups. Likewise, the tuning assembly 300 has a tuning range, discussed in detail below, that allows a single setup to process workpieces with a wider range of tolerances than existing devices. In another example, if mixed materials are used in a stack-up (e.g., two or more pieces) that is to be cold-worked, the tuning assembly 300 can be used to tailor a common ground expansion amount or enables an operator to use two separate expansion amounts in two separate operations without needing to change tools.

In a further aspect, the processing tool 100 can also include a number of sensors or transducers to sense, measure or detect various operational conditions or parameters. Such are illustrated and/or discussed with reference to FIGS. 6 and 7.

Each of these aspects will now be described in greater detail.

II. Expansion Assembly

As illustrated in FIGS. 1-4, the expansion assembly 200 includes a mandrel or core element 210 and a plurality (e.g., four) expansion segments 220.

The core element 210 may be a generally elongated member, and has one or more bearing surfaces 212. The bearing surfaces 212 of the core element 210 may be beveled, tapered or otherwise contoured. This taper may be in the range of 1.5° to 2.5°. Such a taper angle has been found to not have problems with binding. As illustrated, the core element 210 has four bearing surfaces. In other embodiments, the core element 210 may have a greater number of bearing surfaces (e.g., five, six, eight, or more) or fewer contact surfaces (e.g., three, two, one). The core element 210 may take the form of a shaft, rod, link, shank, elongate member, or other member suitable for driving the expansion segments.

The expansion segments 220 each have a contact surface 224 (e.g., outer surface) that in use contacts either an expandable member, or an interior surface of a hole in the primary workpiece. The expansion segments 220 each have a driven surface (e.g., inner surface) 222, which in use is contacted by the bearing surfaces 212 of the core element. The driven surfaces 222 of the expansion segments 220 may be beveled, tapered or otherwise contoured. For example, driven surfaces 222 of the expansion segments 220 may be beveled, tapered or otherwise contoured to be complementary bevel, taper or contour of the second surfaces 212 of the expansion segments 220.

The expansion segments 220 may be arrayed in a generally annular arrangement. The expansion segments 220 may be retained, and optionally biased, by one or more retainment members (not shown), for instance a pair of bands. The bands may bias or urge the expansion segments 220 toward a first, radially contracted or unexpanded configuration.

The expansion segments 220 could be cut from a cylindrical stock piece machined to a larger outside diameter than required. When cutting the individual segments, the cut width could be enlarged. When the expansion segments 220 are assembled, the resulting combined shape of the expansion segments 220 would be an “out of round” (non-round) mandrel. This shape could advantageously create enhance resistance to torque during expansion. The cost of manufacturing conventional mandrels is greatly increased if they are made non-round. By contrast, the combined structure of the expansion segments 220 could be made non-round with a marginal increase in manufacturing cost.

The mandrel or core element 210 is received in a central passageway 240 formed between the expansion segments 220, for translation therethrough. When the core element 210 is in a first position (not depicted), the expansion segments 220 are in first, radially contracted or unexpanded configuration. As the core element 210 is translated to a second position, as shown in, for example, FIG. 2, the bearing surfaces 212 of the mandrel or core element 210 contact the driven surfaces 222 of the expansion segments 220, driving the expansion segments 220 radially outward, toward a second, radially expanded configuration.

Thus, the expansion assembly 200 can be resiliently and controllably expanded and contracted. As used herein, the term “resilient” is a broad term and includes, without limitation, being capable of withstanding working loads or movements without appreciable permanent or plastic deformation. In some embodiments, the expansion segments 220 of the resilient expansion assembly 200 can be moved from the first configuration to the second configuration repeatedly without appreciable permanent or plastic deformation. Of course, there may be a minimal degree of localized plastic yielding even though the expansion assembly generally experiences elastic deformation. In some embodiments, visual inspection can be used to determine whether there is appreciable plastic deformation. After the expansion segments 220 are actuated, any plastic deformation in the expansion assembly 200 may not be recognizable upon visual inspection with the naked eye. In some preferred embodiments, the deformation of the expansion assembly 200 is substantially elastic deformation during operation. Accordingly, the resilient expansion assembly 200 can be actuated any desired number of times.

Additionally or alternatively, the expansion assembly 200, or a portion thereof, can contain a liner, lubricant, combinations thereof, or other structure that reduces or increases the frictional interaction between the core element 210 and expansion segments 220. In some embodiments, a friction reducer in the form of a lubricant is applied to the bearing surfaces of the expansion assembly 200, expansion segments 220, and/or core element 210. For example, the inner surfaces 222 of the expansion segments 220 can be coated with a lubricant for minimizing frictional interaction between the core element 210 and expansion segments 220. A coating (e.g., polymer, such as synthetic resins like polytetrafluoroethylene (PTFE), TEFLON®, nylon, NEDOX® CR+, blends, mixtures, etc.) can be used to reduce frictional forces. Other surface treatments can be used to achieve the desired frictional interaction between moving components of the processing tool 100.

The expansion assembly 200 may be used to install an expandable member in a hole in a primary workpiece. The expansion assembly 200 (preferably in the fully collapsed configuration or partially expanded configuration) can be sized to tightly receive the expandable member to form, for example, an interference fit (e.g., a slight interference fit). In other embodiments, the expansion assembly 200 is sized to allow some play between the expandable member and the expansion segments 220. Alternatively, the expansion assembly 200 may be used to radial expand and/or cold work an opening or hole without installation of an expandable member therein or thereto.

The processing tool 100 can be used to expand the expandable member even though there is limited or no backside access. To position the expandable member in the hole of the workpiece, the unexpanded expansion portion and associated expandable member are inserted into the hole. In some embodiments, the hole can be sized to closely receive the expandable member to form a slight interference fit.

During the expansion process, the elongate expansion segments 220 are generally expanded radially outward. In the illustrated embodiment, the expansion segments 220 radially expand without pivoting. As such, the portions of the expansion segments 220 contacting the expandable member can be generally expanded uniformly along their lengths, thereby ensuring proper placement of the expandable member in the hole. This uniform expansion can minimize, limit, or substantially prevent axial displacement of the expandable member relative to the hole. The expandable member, for example, can be generally axially fixed relative to the longitudinal axis of the hole during the expansion process.

Advantageously, the expansion segments 220 can protect the expandable member from the linear movement of the core element 210. As the expansion portion expands outwardly, the expansion segments 220 can be axially stationary relative to the hole, thus minimizing, limiting, or preventing frictional interaction and wear between the expansion assembly and the expandable member.

The processing system can be used with one or more clamps or other positioning devices. If the installer has backside access, a clamp (e.g., a C-clamp) can help position the processing tool 100 relative to the primary workpiece. The processing tool 100 can also be used without a positioning device, unlike traditional mandrel installation systems. Traditional mandrel installation systems react relatively large axial reactive forces to the installer requiring clamping devices for proper installation. These axial forces may cause undesirable movement between a bushing and workpiece, thus requiring a clamp for proper installation.

Because the expansion segments 220 expands generally radially outward (not linearly through the expandable member), the expansion assembly 200 can be easily held within the expandable member without using a clamp. The reactive forces from the core element 210 are transferred to the processing tool 100 via the cap 170. The installer can conveniently position the expansion assembly 200 and an expandable member within the hole of the primary workpiece with minimal insertion forces, thereby eliminating the need for any clamps. The installer can therefore manually hold the processing tool 100 in proper position during the expansion process without the need of clamps or other holding devices.

To facilitate removal from an installed expandable member, a clearance fit can be formed between the collapsed expansion segments 220 and expandable member. Accordingly, the expansion assembly 200 can be easily removed from the expandable member and used again to install another expandable member.

The processing tool 100 of FIG. 1 can also be used to treat one or more features of a primary workpiece, without installing an expandable member. The processing tool 100, for example, can be used to expand a hole in a similar manner as the expandable member described above. For example, FIGS. 8A and 8B illustrate the expansion assembly 200 treating a hole 510 in a primary workpiece 500. In FIG. 8A, a portion of the expansion assembly 200 is inserted into the hole 510. The processing tool 100 can be activated to drive the core element 210 longitudinally, thereby expanding the expansion segments 220 and associated hole 510, as shown in FIG. 8B. As can be seen in FIGS. 8A and 8B, the inclusion of the bands 250 a and 250 b ensures a uniform radial expansion of the expansion segments 220 along the length of the hole 510. For cold expansion, the expansion assembly can be expanded to cold work the hole to produce residual stresses in the material forming the hole. Of course, the expansion assembly 200 can also be used to perform other types of expansion processes.

As noted above, there may be small gaps between adjacent edges of neighboring expansion segments 220 prior to expansion, which gaps increase as the expansion segments 220 are radially expanded outwardly in response to translation of the core element 210 outwardly with respect to the processing tool 100. Alternatively, the adjacent edges may be in contact with one another prior to radial expansion, essentially eliminating any gaps. The expansion process may leave longitudinally extending ridges, corresponding to the gaps between adjacent segments 220, in the material of the workpiece or expandable element that is contacted by the contact surfaces 224 of the expansion segments 220. These ridges can be removed by reaming or other processing.

In another example, the expansion assembly can be used to eliminate the ridges created by the gaps between the expansion elements 220. After a first expansion, which creates the ridges, the expansion assembly could be retracted, rotated by, for example, 45° (in the case of an assembly 200 with four segments), and expanded a second time. The second expansion would flatten the ridges, and possibly avoid the need to ream the hole post installation, or at least reduce the amount of reaming or further processing that is necessary. In another example, the expansion segments 220 could include surface features that create longitudinally extending grooves for the passage of lubricant in, for example, an installed bushing. This could advantageously reduce the machining costs associated with machining lubrication grooves as a separate step. In some cases, creating the lubrication grooves with the expansion segments 220 could allow the creation of grooves that could not be machine practically.

In other examples, the expansion segments 220 can be used to create other functional features in a work piece and/or expandable member. For example, the contact surface 224 of the expansion segments 220 could include a ring portion with a slightly larger diameter on one or both opposite ends in a longitudinal direction. This ring portion (or portions) could be used to provide extra expansion to one or both ends of an expandable member, such as a bushing. This extra expansion could provide a mechanical lock increasing the pushout resistance. The indentation created in the expandable member would be cleaned up by a final reaming step. In this example, the expansion elements 220 are made to a particular length for specific applications. The amount the diameter of the ring portion can be increased is limited by the amount of clearance needed to allow the expansion segments 220 to access the hole and still maintain a clearance. The larger the ring portions are made, the more the segments 220 would need to be able to collapse prior to expansion. As a result, the gaps between the adjacent segments 220 would be larger in the expanded state. It has been found that it does not require a great variation in the amount of difference in the diameter of the ring portion and the diameter of the other portions of the of the expansion segments 220 to create much higher retention of an installed expandable element.

In another example, one end of the expansion segments 220 could include the ring portion to provide extra expansion at portion of an expandable member that extends beyond one end of a workpiece in order to retain a washer against that one end of the workpiece. In effect, the additional expansion in the area that includes the washer would create a captured flange. In conventional systems, it is sometimes difficult to achieve enough retention, as the flange and the bushing are typically the same material. Using the ring configuration on the expansion segments 220 may reduce this difficulty. The captured flange could be put on either end, maybe even both.

In another example, a ridge on at least one of the expansion segments 220 could be used to create a longitudinal groove for the purpose of, for example, bushing rotational resistance. The groove would create a mechanical lock and a final reaming step could be used to clean up the inner diameter.

In another example, at least one of the expansion segments 220 includes a longitudinally extending ridge that creates a longitudinal groove to create a key way within an expandable member, such as a bushing, during installation. The key way could accommodate a spherical bearing that is slid into the bushing after installation. The key way provides rotational resistance for the bearing.

The expansion assembly 200 could also be used with a sleeve. Such a sleeve could be arranged between the contact surfaces 224 of the expansion segments 220 and the surface to be contacted by the expansion assembly 200 during expansion. The inclusion of the sleeve could reduce the size of the longitudinally extending ridges created by the expansion segments 220 during expansion. The sleeve could also help the expansion segments 220 release from an expandable member that is being installed in the workpiece. For example, if the size of the gap between adjacent segments 220 were to be increased to allow the segments 220 to collapse to a smaller size in a retracted state, the inclusion of a sleeve may be useful to reduce the size of the resulting longitudinal ridges and release the expansion segments 220 from a workpiece or expandable member.

It may be advantageous to use sleeves with difference thickness for different applications. For example, a thicker sleeve might be used if the size of the gap between adjacent segments 220 were to be increased. The sleeve could include a single, longitudinally extending slot or the sleeve might be matched segments with a combined diameter very close to the hole diameter of the workpiece or expandable element, to help minimize the resultant longitudinally extending ridge.

While a specific expansion assembly 200 has been illustrated and described, many of the structures and acts described herein can be employed with other expansion assemblies. For example, the processing tool 100 may operate using an expansion assembly including an expansion jaw having plurality of elongate members that pivot radially outward. Such may not realize as uniform expansion as the expansion assembly 100 described herein, yet may still produce desired results. The tuning assembly 300, discussed below, may be employed with such an expansion jaw. The sensing discussed below may also be employed with such an expansion jaw. Also, the processing tool 100 may operate with more traditional mandrels, which are drawn through either an expandable member to be secured in a hole or through a hole without an expandable member. The various control systems and method described herein, as well as the storage systems and methods may be employed with such conventional mandrels.

III. Tuning Assembly

As discussed above, the tuning assembly 300 gives operators the ability to adjust to multiple scenarios without needing to switch to new tooling. FIGS. 1-4 illustrate an example that includes a tuning assembly 300. However, the expansion assembly 200 need not be used with tuning assembly 300, and can be coupled to a processing tool 100 that does not include a tuning assembly 300.

The tuning assembly 300 includes a tuning cylinder 310 and an index ring 320. The nose cap 170 is mounted to a portion 314 of the tuning cylinder 310. A threaded portion 316 of the tuning cylinder 310 is screwed into a threaded portion 164 of the front housing 160 of the processing tool 100. A spring 330 biases the tuning cylinder 310 and the front housing 160 apart. By adjusting the relative position of the tuning cylinder 310 and the front housing 160 in a longitudinal direction, the penetration depth of the core element 210 into the expansion segments 220 can be adjusted. In particular, as discussed above, the flanges 226 of the expansion segments 220 are seated in the nose cap 170 between the retention device 230 and an interior surface 174 of the nose cap 170. As the nose cap 170 is fixed relative to the tuning cylinder 310 in the direction of linear travel of the core element 210, translating the tuning cylinder 310 relative to the processing tool 100 also causes the expansion segments 220 seated within the nose cap 170 to translate relative to the processing tool 100. On the other hand, the core element 210 is fixed to the piston 130 of the processing tool 100. Thus, the expansion segments 220 are caused to translate relative to the core element 210 when the tuning cylinder 310 translates relative to the front housing 160.

The relative position of tuning cylinder 310 and the front housing 160 is adjusted with an index ring 320. The index ring 320 is fixed with respect to the tuning cylinder 310 in a rotational direction about the longitudinal axis of the processing tool by way of pins 340 that are seated in blind holes 312 in the tuning cylinder 310 and extend through slots 322 in the index ring. The index ring 320 can translate in the longitudinal direction relative to the tuning cylinder 310 for a distance defined by the length of the slots 322. The index ring 320 includes a plurality of discrete positions (in this example 16) that can be selected by aligning any one of the holes 326 (FIG. 4B) drilled in an array on the back side of the index ring 320 with the pin 345 that is seated in the blind hole 162 of the front housing element 160 of the processing tool 100. The index ring 320 further includes a plurality of indicia 324 that assist an operator in recognizing which position has been selected.

Rotating the index ring 320 between selected positions also causes the tuning cylinder 310 to rotate. As the threaded portion 316 of the tuning cylinder 310 is screwed into the threaded portion 164 of the front housing 160, rotating the tuning cylinder 310 relative to the front housing 160 causes the tuning cylinder 310 to translate relative to the front housing 160 by an amount determined by the thread pitch of the threaded portions 316 and 164. As noted above, this relative motion of the front housing 160 and the tuning cylinder 310 also changes a penetration amount of the core element 210 into the expansion segments 220. The radial expansion amount of the expansion segments 220 is then changed by an amount that depends on both the amount of reduction or addition of penetration depth in the longitudinal direction and the taper angles of the surfaces 222 of the expansion segments 220 and the taper angles of the surfaces 212 of the core element 210.

Thus, the expansion amount of the expansion segments 220 can be finely tuned by adjusting a combination of the taper angles of the surfaces 222 and 212, the thread pitch of the threaded portions 316 and 164, and the spacing and amount of selected positions on the index ring as defined by the holes 326. These variables determine a tuning range of the tuning assembly 300.

In this manner, the tuning assembly 300 gives operators the ability to adapt to various work requirements without needing to undergo extensive changes in tooling or setup. Instead, an operator can merely rotate the index ring 320 to a desired setting depending on the scenario. For example, if a single job requires workpieces having different thicknesses to be worked, the tuning assembly 300 allows the operator to adjust the expansion amount accordingly without require multiple setups. Likewise, when manufacturing tolerance would ordinarily require multiple setups, the tuning assembly 300 has a tuning range that allows a single setup to process workpieces with a wider range of tolerances than existing devices.

IV. Sensors

The processing tool 100 can also include a number of sensors or transducers to sense, measure or detect various operational conditions or parameters.

For example, the processing tool 100 may include a number of pressure sensors 420 coupled to sense pressure supplied to the drive system hydraulic cylinder 120. Various types of pressures sensors may be employed. For example, a pressure sensor or transducer 420 is illustrated in FIG. 6. Multiple pressure sensors 420 may advantageously be positioned at or proximate the processing tool 100, to avoid losses associated with the conduits, lines and other structures between a hydraulic reservoir (not depicted) and the cylinder 120. This may produce more accurate determination of pressure, which may be particularly advantageous as explained in detail herein with reference to various method of operation.

Also for example, the processing tool 100 may include a number of position sensors coupled to sense a position of a moveable element, for example a position of the piston 130. Various types of position sensors may be employed. For example FIG. 7 illustrates a linear variable Linear Variable Differential Transformer (LVDT) 440. The position sensor(s) 440 may advantageously be positioned at a face of the piston 130 (FIG. 2), for example between rearwardly facing face of the piston 130 and an opposing wall of the cylinder 120 (FIG. 2). This may produce accurate determinations of position, travel or stroke, which may be particularly advantageous as explained in detail herein with reference to various method of operation.

The process tool 100 may also include an indicator to alert the operator that the actuator has reached the full forward position for which it was calibrated. Such an indicator can be located in the rear of the tool, for example, near the LVDT, and may indicate when a drive member or actuator has reached a full forward position,

As another example, the processing tool 100 may include a number of actuation sensors (not shown) coupled to sense or detect activation by an end user, for example a pull of trigger 112 or other switch activation. Various types of activation sensors may be employed, for example contact sensors. Accurate determinations of actuation may be particularly advantageous as explained in detail herein with reference to various method of operation.

As yet another example, the processing tool 100 may include a number of accelerometers (not shown) to sense or detect orientation and/or acceleration or movement of the processing tool. Various types of accelerometers may be employed, for example 3-axis accelerometers. Accurate determinations of orientation or movement may be particularly advantageous as explained in detail herein with reference to various method of operation.

Storage, analysis, and actions taken as a result of information gathered from sensors associated with the processing system are discussed in more detail in U.S. provisional patent application Ser. No. 61/592,500, entitled “SMART INSTALLATION/PROCESSING SYSTEMS, COMPONENTS, AND METHODS OF OPERATING THE SAME,” and U.S. non-provisional patent application Ser. Nos. 13/750,604 and 13/750,607, the contents of each of which are incorporated by reference herein in their entirety. For example, the noted provisional application discusses that information regarding performance of the process and/or materials may be stored, for example a hole-by-hole or a workpiece-by-workpiece basis, allowing validation of processing. Information also allows dynamic operation of the processing tool. Analysis of response relationships (e.g., pressure or force versus position or distance) may provide insights into the process and materials, and/or facilitate the real-time feedback including control, alerts, ordering replacement for consumable components. While the figures of the present disclosure illustrate a particular expansion assembly, other structures may be employed in combination with various aspects of the present disclosure. For example, the structures described in U.S. Pat. No. 8,069,699, which is incorporated herein by reference in its entirety.

Employing sensors allows more precise control over the processing operations than conventional processing tools. Such, for example, allows installation of expandable members to size. Respective dimensional variation of the hole, mandrel, and expandable member to be installed, as well as variation in the material characteristics (e.g., yield strength) of the primary work piece results in a tolerance stack up. That is, these individual variances from nominal values accumulate for each installation. In contrast to conventional processing tools, the processing systems described herein allow installing expandable members to size, (FORCEMATE TO SIZE™).

Such may advantageously be measured proximate the piston (e.g., at inlet valve to cylinder) via any variety of pressure sensors or transducers. Alternatively, a force sensor may detect an amount of force applied by the piston or some other drive element (e.g., core element, segments of expansion assembly). The second variable may, for example be a position of the piston at any given time, or an amount or distance the piston has traveled. Alternatively, the second variable may be a position of some other drive element (e.g., core element, segments of expansion assembly). Such may be measured via a variety of position sensors, for instance a LVDT, or an encoder for instance an optical encoder or magnetic encoder such as a Reed switch. Other variables may be employed, for example temperature, strain, and/or stress.

V. General Observations

As noted above, the processing system of FIG. 1 may be used to install expandable members. The term “expandable member” is used herein interchangeably with “secondary workpiece”, and is a broad term which includes, but is not limited to, a bushing (including flanged bushing, no flange bushing), washer, sleeve (including a split sleeve), fitting, fastener, grommet, nut plate, conduit connectors, structural expandable member (e.g., expandable members that are incorporated into structural workpieces), and other structures that are suitable for securing to or otherwise physically coupling to a primary workpiece. In some embodiments, the expandable member can be expanded from a first configuration (pre-installed configuration) to a second configuration (installed configuration). For example, the expandable member may be a bushing having at least a portion that is radially expanded an amount sufficient to form an interference fit with an interior surface of a hole in a primary workpiece. The term expandable member refers to a member in a pre-expanded state and a post-expanded state, unless the context dictates otherwise.

In some embodiments, the expandable member is in a form of a non-through hole expandable member. As used herein, the term “non-through hole expandable member” is a broad term and includes, but is not limited to, an expandable member which is sized and dimensioned to fit within a non-through hole, such as a blind hole or other hole that does not extend completely through a workpiece, or otherwise has limited backside access.

Various types of expansion processes can be employed to expand the expandable members. In a cold expansion process, for example, the expandable member is radially expanded, without appreciably raising the temperature of the expandable member, to produce residual stresses in a workpiece and/or expandable member to enhance fatigue performance. The residual stresses are preferably compressive stresses that can minimize, limit, inhibit, or substantially prevent initiation and/or crack propagation.

The various embodiments described above can be combined to provide further embodiments. All patents and publications mentioned herein are hereby incorporated by reference in their entireties. Except as described herein, the embodiments, features, systems, devices, materials, methods and techniques described herein may, in some embodiments, be similar to any one or more of the embodiments, features, systems, devices, materials, methods and techniques described in U.S. Pat. Nos. 3,566,662; 3,892,121; 4,187,708; 4,423,619; 4,425,780; 4,471,643; 4,524,600; 4,557,033; 4,809,420; 4,885,829; 4,934,170; 5,083,363; 5,096,349; 5,405,228; 5,245,743; 5,103,548; 5,127,254; 5,305,627; 5,341,559; 5,380,111; 5,433,100; 8,069,699; and in U.S. patent application Ser. Nos. 09/603,857; 10/726,809; 10/619,226; 10/633,294, and 11/897,270, which are incorporated herein by reference. In addition, the embodiments, features, systems, devices, materials, methods and techniques described herein may, in certain embodiments, be applied to or used in connection with any one or more of the embodiments, features, systems, devices, materials, methods and techniques disclosed in the incorporated U.S. patents and patent applications.

The various primary and/or secondary workpieces and consumable components disclosed herein may be formed through any suitable means. For example, the workpieces can be formed through injection molding, casting, rolling, forming, electrical discharge machining, other machining, and other methods disclosed herein. The various methods and techniques described above provide a number of ways to carry out the various embodiments. Of course, it is to be understood that not necessarily all objectives or advantages described may be achieved in accordance with any particular embodiment described herein. Thus, for example, those skilled in the art will recognize that the methods may be performed in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objectives or advantages as may be taught or suggested herein.

Furthermore, the skilled artisan will recognize the interchangeability of various features from different embodiments disclosed herein. Similarly, the various features and acts discussed above, as well as other known equivalents for each such feature or act, can be mixed and matched by one of ordinary skill in this art to perform methods in accordance with principles described herein. Additionally, the methods which are described and illustrated herein are not limited to the exact sequence of acts described, nor are they necessarily limited to the practice of all of the acts set forth. Other sequences of events or acts, or less than all of the events, or simultaneous occurrence of the events, may be utilized in practicing the embodiments of the invention.

Although the invention has been disclosed in the context of certain embodiments and examples, it will be understood by those skilled in the art that the invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses and obvious modifications and equivalents thereof. Accordingly, it is not intended that the invention be limited, except as by the appended claims. 

What is claimed is:
 1. An expansion assembly, comprising: a plurality of elongated expansion segments, each of the expansion segments having a contact surface and a drive surface; and a first band and a second band coupling the expansion segments into an array with the expansion segments circumferentially distributed about a longitudinal axis, with a passageway extending between the arrayed segments.
 2. The expansion assembly of claim 1, wherein the first band and the second band are located on proximate ends of the expansion segments with respect to a length of the array.
 3. The expansion assembly of claim 1, wherein the first band and the second band are located on opposite sides of a center of a length of the array.
 4. The expansion assembly of claim 1, further comprising a core element that is movable within the passageway along the longitudinal axis from a first position to a second position to drive each respective one of the plurality of expansion segments in a respective radial direction substantially transverse to the longitudinal axis.
 5. The expansion assembly of claim 1, further comprising a core element that is movable within the passageway along the longitudinal axis to expand the expansion segments without pivoting by physical interaction between the core element and the drive surfaces of the plurality of expansion segments.
 6. The expansion assembly of claim 4, wherein the passageway includes a first taper that is defined by the bearing surfaces of the plurality of expansion segments, and the core element includes a second taper.
 7. The expansion assembly of claim 6, wherein the first taper and the second taper are non-conical tapers.
 8. The expansion assembly of claim 6, wherein the drive surface of each of the plurality of expansion segments defines a portion of the first taper, and the second taper of the drive member includes a plurality of planar bearing surfaces that each respectively corresponds to one of the drive surfaces of one of the plurality of complementary segments and which define a portion of the second taper.
 9. The expansion assembly of claim 6, wherein the core has a polygonal cross section with respect to a central axis of the core.
 10. The expansion assembly of claim 1, wherein each of the plurality of expansion segments includes a portion of linearly decreasing thickness along the longitudinal axis.
 11. The expansion assembly of claim 1, wherein the drive surface of each of the plurality of expansion segments is a bevel that extends in a plane oblique to the longitudinal axis.
 12. The expansion assembly of claim 1, wherein the expansion segments each include a respective first and second retainer, and, in use, the first band and the second band are located in respective ones of the first and second retainers.
 13. The expansion assembly of claim 12, wherein at least one of the first and second retainers is a groove in an outer surface of at least one of the plurality of expansion segments.
 14. The expansion assembly of claim 1, wherein the each of the plurality of expansion elements includes a flange that extends radially outward with respect to the contact surface, and the flange is located between the first band and the second band.
 15. The expansion assembly of 1, further comprising: a nose cap including an interior face and through hole; and a retaining member seated within the adjustment cap so that the flange of each of the plurality of expansion elements is secured between the retaining member and the interior face of the nose cap.
 16. The expansion assembly of 1, wherein each of the expansion segments includes a portion on one end of the contact surface with respect to the longitudinal axis that, when the expansion segments are assembled together, forms a ring portion with a first diameter that is larger than a second diameter of the contact surface proximate to a center of the expansion segments with respect to the longitudinal axis.
 17. The expansion assembly of 1, wherein at least one of the expansion segments includes a longitudinally extending ridge on the contact surface.
 18. The expansion assembly of claim 1, wherein the expansion assembly includes four of the expansion segments.
 19. A tuning assembly for use in a processing system that includes an expansion assembly including a plurality of expansion elements, and a drive member that is movable in a longitudinal direction to actuate each respective one of the plurality of expansion segments of the expansion assembly in a respective radial direction substantially transverse to a longitudinal axis of the expansion assembly, the longitudinal direction being substantially parallel to the longitudinal axis, the tuning assembly comprising: a mechanism configured to selectively adjust a maximum radial expansion amount of the expansion assembly without altering a stroke length of the drive member.
 20. The tuning assembly of claim 19, wherein the expansion segments of the expansion system are arranged circumferentially in an array distributed about the longitudinal axis, with a passageway extending between the arrayed expansion segments, the expansion assembly includes a core element movable in the passageway in the longitudinal direction to drive each respective one of the plurality of expansion segments in the respective radial direction by physical interaction between the core element and drive surfaces of the plurality of expansion segments, and the tuning mechanism is configured to translate the expansion segments relative to the core element along the longitudinal axis.
 21. The tuning assembly of claim 20, wherein the processing system includes a housing that houses the drive member, the tuning assembly is coupled to the housing for selective movement with respect to the housing in the longitudinal direction, and the plurality of expansion segments are coupled to the housing so as to be fixed with respect to the housing in the longitudinal direction.
 22. The tuning assembly of claim 21, wherein the tuning assembly is rotatable about the longitudinal axis relative to the housing between a plurality of fixed positions, each fixed position corresponding to a different maximum radial expansion amount of the expansion assembly.
 23. The tuning assembly of claim 19, wherein the tuning assembly is rotatable about the longitudinal axis relative to a housing that houses the drive member between a plurality of fixed positions, each fixed position corresponding to a different maximum radial expansion amount of the expansion assembly.
 24. The tuning assembly of claim 19, wherein the tuning assembly includes a tuning cylinder that is fixed relative to the plurality of expansion segments in the longitudinal direction, and the tuning cylinder is selectively movable relative to a housing that houses the drive member in the longitudinal direction.
 25. The tuning assembly of claim 24, wherein the tuning assembly includes an index ring that is coupled to the tuning cylinder, the index ring fixed relative to the tuning cylinder with respect to a rotational direction about the longitudinal axis, the index ring selectively engageable with the housing at plurality of fixed positions in the rotational direction, each fixed position corresponding to a different maximum radial expansion amount of the expansion assembly.
 26. The tuning assembly of claim 19, wherein the expansion segments are circumferentially distributed in an array about a longitudinal axis, with a passageway extending between the arrayed segments, the expansion assembly includes a core element movable in the passageway in the longitudinal direction to drive each respective one of the plurality of expansion segments in the respective radial direction by physical interaction between the core element and drive surfaces of the plurality of expansion segments, and the tuning assembly is configured to adjust a depth of penetration in the longitudinal direction of the core element into the passageway. 